System, method and apparatus for compressed insulation

ABSTRACT

An insulation product may include a container, a first insulation material forming a first layer inside the container, and a second insulation material forming a second layer inside the container, and the first layer is compressed by the second layer. A structure in a building may include studs, first and second claddings mounted to opposite sides of the studs, and structure spaces defined between the studs and the opposing claddings. A first insulation material may include first layers on and substantially covering a first one of the claddings inside the structure spaces. In addition, a second insulation material may have second layers inside the structure spaces. The first layers are compressed and substantially covered by the second layers, and the second layers substantially cover a second one of the claddings inside the structure spaces.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of and claims priority under 35U.S.C. § 120 to U.S. patent application Ser. No. 16/788,911, entitled“SYSTEM, METHOD AND APPARATUS FOR COMPRESSED INSULATION,” byJean-Philippe NDOBO-EPOY et al., filed Feb. 12, 2020, which is adivisional of and claims priority to U.S. patent application Ser. No.15/223,852, entitled “SYSTEM, METHOD AND APPARATUS FOR COMPRESSEDINSULATION,” by Jean-Philippe NDOBO-EPOY et al., filed Jul. 29, 2016,which application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Application No. 62/198,968, entitled “SYSTEM, METHOD ANDAPPARATUS FOR COMPRESSED INSULATION,” by Jean-Philippe NDOBO-EPOY etal., filed Jul. 30, 2015, all of which are assigned to the currentassignee hereof and incorporated herein by reference in theirentireties.

BACKGROUND OF THE INVENTION Field of the Disclosure

The present invention relates in general to insulation and, inparticular, to a system, method and apparatus for insulation compressedby expanded foam.

Description of the Related Art

The use of insulation to improve the energy efficiency of buildings iswell known. The evolution of the energy codes in the U.S. requiresinsulation materials with a better thermal performance, such as lowerthermal conductivity. The most common insulation products used in theU.S. are fiberglass, such as fiberglass batts 11 (FIG. 1), and closedcell spray foam 13 (FIG. 2).

Closed cell foams give both excellent airtightness and insulation thatis superior to fiberglass, but is much more expensive than fiberglass.Open cell foams are much cheaper than open cell foams, but require muchgreater volumes to achieve the requisite levels of airtightness andinsulation. Due to the high price of closed cell foams, insulationcontractors typically only use a thin layer of them for theairtightness, and complete their insulation installations withinexpensive fiberglass.

The code IECC2012 now requires the following standards for walls. Inclimate zones 3-5, either an R13 (h·ft²·F/Btu) between studs with an R5continuous insulation, or an R20 between studs, which is achievable onlywith closed cell foam. For climate zones 6-8, an R20 between rafters anR5 continuous external insulation is acceptable.

Manufacturing high performing insulation (i.e., with low thermalconductivity) is a challenge because the density must be increased todecrease the radiative transfers. This reduces the speed of productionlines and reduces strongly reduces the compression of products. Forexample, an R11 (with density 1 pound per cubic foot, or lb/ft³) productcan be compressed by a factor of 10 times per bag. An R15 product (1.5lb/ft³) can be compressed by a factor of a maximum of 3 times per bag,which means higher logistic costs, less product per bag, difficulty inmanipulation at job sites and is more difficult to cut.

Currently, an R16 product is not produced in the U.S. R16 is the bestfiberglass product available in Europe. It has very high density at 3lb/ft³, requires super stretching, but is essentially incompressible.Even if such a product were available in the U.S., the market would beunwilling to pay twice the price of an R15 to get an R16. Theseplatforms can limit the insulation effectiveness to below coderequirements. Thus, improvements in insulation continue to be ofinterest.

SUMMARY

Embodiments of a system, method and apparatus for compressed insulationare disclosed. For example, an insulation product may include acontainer, a first insulation material forming a first layer inside thecontainer, and a second insulation material forming a second layerinside the container, and the first layer is compressed by the secondlayer.

In another embodiment, a method of fabricating an insulation product mayinclude providing a container; installing a first layer of a firstinsulation material on an interior surface of the container; and theninstalling a second layer of a second insulation material between thefirst layer and an opposite interior surface of the container, such thatthe second insulation material expands and compresses the first layer.

In an alternate embodiment, a method of fabricating an insulationproduct may include defining a structure in a building, the structurehaving studs, claddings mounted to the studs, and structure spacesbetween the studs and claddings; installing first layers of a firstinsulation material and substantially covering a first one of thecladdings inside respective ones of the structure spaces; and theninstalling second layers of a second insulation material in thestructure spaces between the first layers and an opposite cladding ofthe structure, such that the second insulation material expands andcompresses the first layers.

In yet another embodiment, a structure in a building may include studs,first and second claddings mounted to opposite sides of the studs, andstructure spaces defined between the studs and the opposing claddings. Afirst insulation material may include first layers on and substantiallycovering a first one of the claddings inside the structure spaces. Inaddition, a second insulation material may have second layers inside thestructure spaces. The first layers are compressed and substantiallycovered by the second layers, and the second layers substantially covera second one of the claddings inside the structure spaces.

Another embodiment may include a structure in a building having studs,first and second claddings mounted to opposite sides of the studs, andstructure spaces defined between the studs and the claddings. Twodifferent types of insulation may be used in the structure spaces, witha second type of the insulation compressing a first type of theinsulation. In addition, at least about 80% of the structure meets aspecification including: a thermal conductivity (λ) in a range of about0.14 Btu·in/(ft²·hr·F) to about 0.28 Btu·in; a thermal resistance(R-value) in a range of about R13 to about R22; an acoustic propertycomprising noise reduction in a range of about 33 dB to about 40 dB; andan average density in a range of about 0.063 lb/ft³ to about 1.87lb/ft³.

The foregoing and other objects and advantages of these embodiments willbe apparent to those of ordinary skill in the art in view of thefollowing detailed description, taken in conjunction with the appendedclaims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features and advantages of theembodiments are attained and can be understood in more detail, a moreparticular description may be had by reference to the embodimentsthereof that are illustrated in the appended drawings. However, thedrawings illustrate only some embodiments and therefore are not to beconsidered limiting in scope as there may be other equally effectiveembodiments.

FIG. 1 is an isometric photograph of conventional fiberglass insulationin a home.

FIG. 2 is an isometric photograph of conventional closed cell spray foaminsulation in a home.

FIG. 3 is a schematic, partially sectioned, isometric view of anembodiment of compressed insulation product.

FIG. 4 is an isometric view of an embodiment of an open container havinga first layer of insulation installed therein.

FIGS. 5A-5D are sequential, sectional views of an embodiment of steps ofa method.

FIG. 6 is a Larkin curve diagram illustrating the performance of variousembodiments.

The use of the same reference symbols in different drawings indicatessimilar or identical embodiments.

DETAILED DESCRIPTION

Embodiments of a system, method and apparatus for compressed insulationare disclosed. For example, as shown in FIG. 3, an insulation product 21may include a container 23 that is portable. A first insulation materialmay form a first layer 25 inside the container 23. A second insulationmaterial may form a second layer 27 inside the container, and the firstlayer is compressed by the second layer. In some versions, the first andsecond layers 25, 27 substantially fill the container 23.

Some embodiments of the insulation product 21 may include the secondlayer 27 not penetrating into the first layer 25. For example, the firstlayer 25 can include at least one liner, facing and barrier 29, betweenthe first layer 25 and the second layer 27. Versions of the at least oneliner, facing and barrier 29 may include at least one of paper, plastic,glass mat and dense glass mat. The at least one liner, facing andbarrier 29 can partially or completely separate the first layer 25 andthe second layer 27.

In an example, the first layer 25 can substantially cover an entireinterior surface 31 of the container 23. The second layer 27 cansubstantially cover an entire opposite interior surface 33 of thecontainer 23. The second layer 27 can substantially cover and compressan entire surface 35 of the first layer 25.

In other embodiments, the first insulation material may include one ormore materials. For example, the first insulation material can includeat least one of a compressible insulation, an organic material, acompressible mineral material, a synthetic material, cellulose,fiberglass, polyester fibers, polyethylene fibers, glass wool, stonewool, sheep wool, wood fibers, cotton, hemp, flax, cork, straw, feathersand chopped recycled cloth.

Likewise, embodiments of the second insulation material may include oneor more materials. For example, the second insulation material caninclude at least one of a foam, a spray foam, a closed cell spray foam,and a slow rise spray foam. In one version, the second insulationmaterial may include at least one of isocyanate, methylene diphenyldiisocyanate (MDI), polyol resin and polyether polyols. In anotherversion, one or more commercially available expanding foam materials canbe used.

Embodiments of the second insulation material may include an airtightlayer in the insulation product. The airtight layer may include an airpermeance of less than about 0.004 L/(s·m²) @ 75 Pa for a one inchthickness. In addition or alternatively, the second insulation materialcan have a water vapor permeance of not greater than about 2 perms/inch.

Other examples of the second insulation material may include anexpansion factor of at least about 2×, such as at least about 5×, atleast about 10×, at least about 20×, at least about 50×, or even atleast about 100×. Other versions of the second insulation material caninclude an expansion factor of not greater than about 200×, such as notgreater than about 400×, not greater than about 600×, not greater thanabout 800×, or even not greater than about 1000×. Other embodiments ofthe second insulation material can have an expansion factor in a rangebetween any of these values.

Embodiments of the first insulation material can have a higher densitythan the second insulation material. In other versions, the secondinsulation material can have a higher density that the first insulationmaterial.

In some examples, the first insulation material can have an uncompresseddensity. For example, the first insulation material can have anuncompressed density of at least about 0.35 lb/ft³. In other versions,the first insulation material can have an uncompressed density of atleast about 0.5 lb/ft³, such as at least about 0.62 lb/ft³, at leastabout 0.75 lb/ft³, at least about 0.94 lb/ft³, or even at least about1.25 lb/ft³. In other examples, the first insulation material can havean uncompressed density that is not greater than about 2.8 lb/ft³. Instill other versions, the first insulation material can have anuncompressed density cab be not greater than about 2.5 lb/ft³, such asnot greater than about 2.2 lb/ft³, not greater than about 1.87 lb/ft³,or even not greater than about 1.56 lb/ft³. In addition, embodiments ofthe first insulation material can have an uncompressed density in arange between any of these values.

In other examples, the first insulation material can have a compresseddensity. For example, the first insulation material can have acompressed density (e.g., such as inside the container 23) of at leastabout 0.62 lb/ft³. In other versions, the first insulation material canhave a compressed density of at least about 0.75 lb/ft³, such as atleast about 0.94 lb/ft³, at least about 1.25 lb/ft³, or even at leastabout 1.56 lb/ft³. In other versions, the first insulation material canhave a compressed density of not greater than about 3 lb/ft³. The firstinsulation material also can have a compressed density of not greaterthan about 2.8 lb/ft³, such as not greater than about 2.5 lb/ft³, notgreater than about 2.2 lb/ft³, or even not greater than about 1.87lb/ft³. In addition, embodiments of the first insulation material canhave a compressed density in a range between any of these values.

Embodiments of the second insulation material can have a density of atleast about 0.25 lb/ft³, such as at least about 0.4 lb/ft³, at leastabout 1 lb/ft³, at least about 1.5 lb/ft³, or even at least about 2lb/ft³. In other versions, the second insulation material can have adensity of not greater than about 3 lb/ft³, such as not greater thanabout 4 lb/ft³, not greater than about 5 lb/ft³, not greater than about6 lb/ft³, or even not greater than about 8 lb/ft³. In addition,embodiments of the second insulation material can have a density in arange between any of these values.

In some versions, the first insulation material can be compressed by atleast about 10%. In other examples, the first insulation material can becompressed by at least about 20%, such as at least about 30%, at leastabout 40%, or even at least about 45%. In other versions, the firstinsulation material can be compressed by not greater than about 80%,such as not greater than about 75%, not greater than about 70%, notgreater than about 65%, or even not greater than about 60%. In addition,embodiments of the first insulation material can be compressed in arange between any of these values.

In addition, the insulation product can have a thickness ratio (TR) thatmay be defined as a thickness of the compressed first layer (TF; seeFIG. 3) to a thickness of the second layer (TS). For example, thethickness ratio (TR=TF/TS) can be at least about 0.1, such as at leastabout 0.2, at least about 0.3, at least about 0.4, or even at leastabout 0.5. In other versions, the thickness ratio can be not greaterthan about 0.9, such as not greater than about 0.8, not greater thanabout 0.7, or even not greater than about 0.6. In addition, embodimentsof the insulation product can have a thickness ratio in a range betweenany of these values.

Embodiments of the first insulation material may include an uncompressedthermal resistance (R-value). For example, the first insulation materialcan have an uncompressed R-value of at least about R10, such as at leastabout R11, at least about R12, at least about R13, at least about R14,or even at least about R15. In other examples, the first insulationmaterial can have an uncompressed R-value of not greater than about R25,such as not greater than about R24, not greater than about R23, notgreater than about R22, not greater than about R21, or even not greaterthan about R20. In addition, embodiments of the first insulationmaterial can have an uncompressed R-value in a range between any ofthese values.

Other embodiments of the first insulation material may include acompressed R-value. For example, the first insulation material can havea compressed R-value of at least about R12, such as at least about R14,at least about R16, at least about R18, or even at least about R20. Inother versions, the first insulation material can have a compressedR-value of not greater than about R34, such as not greater than aboutR32, not greater than about R30, not greater than about R28, or even notgreater than about R26. In addition, embodiments of the first insulationmaterial can have a compressed R-value in a range between any of thesevalues.

Versions of the first insulation material may include an uncompressedthermal conductivity (λ). For example, the first insulation material canhave an uncompressed λ, of at least about 0.31 Btu·in/(ft²·hr·F), suchas at least about 0.30 Btu·in, at least about 0.29 Btu·in, at leastabout 0.28 Btu·in, or even at least about 0.27 Btu·in. Other versions ofthe first insulation material may include an uncompressed λ, of notgreater than about 0.22 Btu·in, not greater than about 0.23 Btu·in, notgreater than about 0.24 Btu·in, not greater than about 0.25 Btu·in, suchas not greater than about 0.26 Btu·in. In addition, embodiments of thefirst insulation material can have an uncompressed λ, in a range betweenany of these values.

Other versions of the first insulation material may include a compressedλ. For example, the first insulation material can have a compressed λ,of at least about 0.31 Btu·in/(ft²·hr·F), such as at least about 0.29Btu·in, at least about 0.28 Btu·in, at least about 0.27 Btu·in, or evenat least about 0.26 Btu·in. Other examples of the first insulationmaterial can have a compressed λ, of not greater than about 0.22 Btu·in,such as not greater than about 0.23 Btu·in, not greater than about 0.24Btu·in, not greater than about 0.25 Btu·in, or even not greater thanabout 0.26 Btu·in. In addition, embodiments of the first insulationmaterial can have a compressed λ, in a range between any of thesevalues.

Embodiments of the second insulation material may include a thermalconductivity (λ) as well. For example, the second insulation materialcan have a λ, of at least about 0.18 Btu·in/(ft²·hr·F), such as at leastabout 0.17 Btu·in, or even at least about 0.16 Btu·in. Alternateversions of the second insulation material can have a λ, of not greaterthan about 0.14 Btu·in, such as not greater than about 0.15 Btu·in, oreven not greater than about 0.16 Btu·in. In addition, embodiments of thesecond insulation material can have a λ in a range between any of thesevalues.

Some embodiments of the second insulation material can include a thermalresistance (R-value, aged). For example, the second insulation materialcan include an aged R-value of at least about R4/inch, such as at leastabout R5/inch, at least about R5.5/inch, or even at least aboutR5.75/inch. Other versions of the second insulation material can have anaged R-value of not greater than about R7/inch, such as not greater thanabout R6.5/inch, or even not greater than about R6.25/inch. In addition,embodiments of the second insulation material can have an aged R-valuein a range between any of these values.

Embodiments of the insulation product may include an overall, agedR-value, which may vary by size or application. For example, a versionof the insulation product for 2×4 wall stud applications can have anoverall, aged R-value of at least about R12, such as at least about R13,at least about R14, at least about R15, or even at least about R16.Other versions of the insulation product can have an overall, agedR-value of not greater than about R23, such as not greater than aboutR22, not greater than about R21, not greater than about R20, or even notgreater than about R19. In addition, embodiments of the insulationproduct can have an overall, aged R-value in a range between any ofthese values.

Embodiments of the insulation product for 2×6 wall stud applications canhave an overall, aged R-value of at least about R22, such as at leastabout R23, at least about R24, at least about R25, or even at leastabout R26. Other versions of the insulation product for 2×6 wall studapplications can have an overall, aged R-value of not greater than aboutR36, such as not greater than about R35, not greater than about R34, notgreater than about R33, or even not greater than about R32. In addition,embodiments of the insulation product can have an overall, aged R-valuein a range between any of these values.

An example of the insulation product can have an overall acousticproperty comprising a noise reduction or Sound Transmission Class (STC)rating that is an integer rating of how well a building partitionattenuates airborne sound. It is widely used to rate interiorpartitions, ceilings/floors, doors, windows and exterior wallconfigurations (see ASTM International Classification E413 and E90).Embodiments of the insulation product can have a noise reduction of atleast about 33 dB, such as at least about 34 dB, at least about 35 dB,at least about 36 dB, or even at least about 37 dB. In other versions,the insulation product can have a noise reduction of not greater thanabout 38 dB, such as not greater than about 39 dB, or even not greaterthan about 40 dB. In addition, embodiments of the insulation product canhave an overall noise reduction in a range between any of these values.

In some embodiments, the container 23 for the insulation product 21 mayinclude at least one material. For example, the container 23 may includeone or more of a natural material, a synthetic material, a board, wood,gypsum, rigid insulation, oriented strand board (OSB), plywood andparticle board.

In other examples, the container 23 may include a flexural strength(e.g., per ASTM C473 Method A) of at least about 10 lbf, such as atleast about 20 lbf, at least about 30 lbf, at least about 40 lbf, atleast about 50 lbf, or even at least about 60 lbf. In other versions,the container 23 can have a flexural strength of not greater than about300 lbf, such as not greater than about 200 lbf, not greater than about175 lbf, not greater than about 150 lbf, not greater than about 125 lbf,or even not greater than about 100 lbf. In addition, embodiments of thecontainer can have a flexural strength in a range between any of thesevalues.

In one example, the container 23 can be a rectangular box. For example,the rectangular box may include a length L of at least about 1 foot,such as at least about 3 feet, at least about 5 feet, at least about 7feet, or even at least about 9 feet. Other versions of the box can havea length L of not greater than about 36 feet, such as not greater thanabout 24 feet, not greater than about 16 feet, not greater than about 14feet, or even not greater than about 12 feet. In addition, embodimentsof the box can have a length in a range between any of these values.

In another example, the container 23 or box may include a width W of atleast about 6 inches, such as at least about 8 inches, at least about 10inches, at least about 12 inches, or even at least about 14 inches.Other versions can have a width W of not greater than about 16 inches,such as not greater than about 20 inches, not greater than about 24inches, not greater than about 28 inches, not greater than about 32inches, not greater than about 36 inches, not greater than about 40inches, not greater than about 44 inches, or even not greater than about48 inches. Still other embodiments of the box can have a width in arange between any of these values.

Other examples of the container 23 or box may include a depth D of atleast about 3 inches, such as at least about 3.5 inches, at least about4 inches, or even at least about 4.5 inches. Some versions of the boxcan have a depth D of not greater than about 5 inches, such as notgreater than about 5.5 inches, or even not greater than about 6 inches.Other embodiments of the box can have a depth in a range between any ofthese values.

In yet another example, the first layer 25 can be substantially uniform,and the second layer 27 can be substantially uniform. Each layer 25, 27can have has a flatness, which may be characterized in terms of maximumroughness of a surface. For example, Rmax may be defined as the distancemeasured from the top of the highest peak to the bottom of the lowestvalley of a surface texture. For the surfaces of the first and secondlayers 25, 27, Rmax can be at least about 0.08 inches, such as at leastabout 0.16 inches, at least about 0.24 inches, at least about 0.31inches, or even at least about 0.39 inches. In other versions, Rmax canbe not greater than about 0.79 inches, such as not greater than about0.71 inches, not greater than about 0.63 inches, not greater than about0.55 inches, or even not greater than about 0.47 inches. In addition,embodiments of the layers can have an Rmax in a range between any ofthese values.

In some embodiments, the container 23 (FIG. 3) can be cut to essentiallyany length L, and the container 23 can be cut to essentially any widthW. However, the thickness of the container 23 should not be cut in thedepth direction D, since the thickness and performance of the insulationlayers 25, 27 would be affected by such a cut.

Embodiments of a method of fabricating an insulation product may beperformed at a job site, or as a prefabrication method prior to use at ajob site. For example, the method may include providing a container 23;installing a first layer 25 (FIG. 4) of a first insulation material onan interior surface 31 of the container 23; and then installing a secondlayer 27 (FIG. 3) of a second insulation material between the firstlayer 25 and an opposite interior surface 33 of the container 23, suchthat the second insulation material expands and compresses the firstlayer 25.

In one example of the method, the container 23 can be open (FIG. 4)during the second step, and the container 23 can be closed (FIG. 3)during the third step. In another example of the method, the container23 can have a single aperture 37, and the third step may includeinjecting the second insulation material through the single aperture 37.In still another example of the method, the container 23 may include aplurality of apertures 37, and third step can include simultaneouslyinjecting the second insulation material through all of the plurality ofapertures 37. Embodiments of the third step of the method may includemixing isocyanate and polyol resin. Still other embodiments of themethod may further include at least one of the steps of cutting thecontainer 23 to a desired length L and cutting the container 23 to adesired width W, but not cutting the container 23 in the depth directionD.

In another embodiment, a method of fabricating an insulation product fornew, in-situ building construction may be performed. For example, oneembodiment of the method may include defining a structure 51 (FIG. 5A)in a building. The structure 51 may include studs 53, cladding 55, 57mounted to the studs 53, and structure spaces 59 between the studs 53and claddings 55, 57; installing first layers 25 of a first insulationmaterial and substantially covering a first one of the claddings 55(FIG. 5B) inside respective ones of the structure spaces 59; and theninstalling second layers 27 (FIG. 5C) of a second insulation material inthe structure spaces 59 between the first layers 25 and an oppositecladding 57 of the structure 51, such that the second insulationmaterial expands (FIG. 5D) and compresses the first layers 25.

In other embodiments of the method, the structure spaces 59 can remainopen (analogous to FIG. 4) during the second step, and the structurespaces 59 can be closed (analogous to FIG. 3) during the third step. Inanother example, the first one of the claddings 55 can be an interiorcladding, the second one of the claddings 57 can be an exteriorcladding, the second step can include installing the first layers 25adjacent an interior of the building, and the third step may includeinstalling the second layers 27 adjacent an exterior of the building. Inanother example of the method, the structure 51 can be at least one of afloor with floor spaces, a wall with wall spaces, a ceiling with ceilingspaces, and a roof with roof spaces.

Embodiments of a structure in a building may include studs, first andsecond claddings mounted to opposite sides of the studs, and structurespaces defined between the studs and the opposing claddings. A firstinsulation material may include first layers on and substantiallycovering a first one of the claddings inside the structure spaces. Inaddition, a second insulation material may include second layers insidethe structure spaces, the first layers are compressed and substantiallycovered by the second layers, and the second layers substantially covera second one of the claddings inside the structure spaces. An example ofthe structure can be at least one of a wall with wall spaces, a ceilingwith ceiling spaces, and a roof with roof spaces.

Other embodiments of a structure in a building may include studs, firstand second claddings mounted to opposite sides of the studs, andstructure spaces defined between the studs and the opposing claddings;and, optionally, two different types of insulation in the structurespaces, with a second type of the insulation compressing a first type ofthe insulation. In addition, at least about 80% of the structure canmeet a specification comprising: a thermal conductivity (λ) in a rangeof about 0.14 Btu·in/(ft²·hr·F) to about 0.28 Btu·in; a thermalresistance (R-value) in a range of about R13 to about R22; an acousticproperty comprising noise reduction in a range of about 33 dB to about40 dB; and an average density in a range of about 0.63 lb/ft³ to about1.87 lb/ft³.

Still other embodiments of the system may include a cavity to beinsulated, a flexible compressible insulation portion and an expandingcompressing insulation portion. When the expanding portion is deployed,the compressible portion reduces in volume and moves to a higherdensity, thereby improving its thermal resistance value. In anotherversion, both the first and second insulation materials can becompressed. For example, open cell foam may be injected in a cavity withfiberglass, such that part of the compression will be shared by thefiberglass as well as the open cell foam. In addition, the secondmaterial may comprise a form of cellulose, such as blown fiberglass.

EXAMPLES

In a first example, the product SPI Pour Envelo SFC I 2.0 CG closed cellfoam, available from Specialty Products, Inc., of Lakewood, Wash., wasused to compress the first layer of fiberglass insulation at differentdensities (prior to compression) from R11 (8.5 kg/m³) to R15 (22 kg/m³).When 2 ounces of pour foam per square foot was used in a cavity having athickness of 3.5 inches, the swelling of the foam was relatively unevenwith deviations in compressed thickness of the first layer. For example,one inch of uncompressed insulation varied in compressed thickness from0.5 inch to about 2 inches. Some of the first layer of fibers were notcompressed enough (from about 3.5 inches to 2.5 inches) to have asignificant impact on the thermal conductivity.

In examples where 3.5 ounces of pour foam per square foot were used(which is the maximum amount that can be added in a 3.5 inch cavitywithout bursting it), the foam swelled uniformly to about 2.5 inches,compressing the fibers of the first layer from 3.5 inches to 1 inch.However, for R13 and R15 in the first layer, the compression is too highand the advantage of the compression is lost due to the solid conductionportion of the Larkin curve (FIG. 6), which illustrates the effects ofair, glass and radiation. The Larkin curve shows that the higherdensities yield undesirable higher the solid conduction, with theoptimum performance at about 40 kg/m³.

In examples where R11 was used in the first layer (which is much lighterthan R13 and R15), the compression ranged from about 8 to about 28kg/m³, which corresponds to thicknesses of 3.5 inches to 1 inch. The useof 100% pour foam in the 3.5 inch cavity produced a final product withR20. In contrast, the use of 100% R11 (with no second layer) obviouslyyields an R11 final product, which is inexpensive but performs poorly.However, a final product of R18 is produced with a 70% foam second layerand a 30% fiberglass first layer.

Other versions may include one or more of the following embodiments:

Embodiment 1. An insulation product, comprising: a container; a firstinsulation material forming a first layer inside the container; and asecond insulation material forming a second layer inside the container,and the first layer is compressed by the second layer.

Embodiment 2. The insulation product of any of these embodiments,wherein the first and second layers substantially fill the container.

Embodiment 3. The insulation product of any of these embodiments,wherein the first insulation material has a higher density than thesecond insulation material.

Embodiment 4. The insulation product of any of these embodiments,wherein the second insulation material has a higher density than thefirst insulation material.

Embodiment 5. The insulation product of any of these embodiments,wherein the first insulation material comprises at least one ofcompressible insulation, an organic material, a compressible mineralmaterial, a synthetic material, cellulose, fiberglass, polyester fibers,polyethylene fibers, glass wool, stone wool, sheep wool, wood fibers,cotton, hemp, flax, cork, straw, feathers and chopped recycled cloth.

Embodiment 6. The insulation product of any of these embodiments,wherein the second insulation material comprises at least one of a foam,a spray foam and a slow rise spray foam.

Embodiment 7. The insulation product of any of these embodiments,wherein the second insulation material comprises at least one ofisocyanate, methylene diphenyl diisocyanate (MDI), polyol resin andpolyether polyols.

Embodiment 8. The insulation product of any of these embodiments,wherein the second insulation material comprises at least onecommercially available expanding foam.

Embodiment 9. The insulation product of any of these embodiments,wherein the second insulation material comprises an airtight layer inthe insulation product.

Embodiment 10. The insulation product of any of these embodiments,wherein the airtight layer comprises an air permeance of less than about0.004 L/(s·m²) @ 75 Pa for a one inch thickness.

Embodiment 11. The insulation product of any of these embodiments,wherein the second insulation material has a water vapor permeance ofnot greater than about 2 perms/inch.

Embodiment 12. The insulation product of any of these embodiments,wherein the first layer comprises at least one liner, facing and barrierbetween the first layer and the second layer.

Embodiment 13. The insulation product of any of these embodiments,wherein the at least one liner, facing and barrier comprises at leastone of paper, plastic, glass mat and dense glass mat.

Embodiment 14. The insulation product of any of these embodiments,wherein the second layer does not penetrate into the first layer.

Embodiment 15. The insulation product of any of these embodiments,wherein the second insulation material comprises a closed cell sprayfoam.

Embodiment 16. The insulation product of any of these embodiments,wherein the first insulation material comprises: an uncompressed densityof at least about at least about 0.35 lb/ft³, at least about 0.5 lb/ft³,at least about 0.62 lb/ft³, at least about 0.75 lb/ft³, at least about0.94 lb/ft³, at least about 1.25 lb/ft³, and not greater than about 2.8lb/ft³, not greater than about 2.5 lb/ft³, not greater than about 2.2lb/ft³, not greater than about 1.87 lb/ft³, not greater than about 1.56lb/ft³; and a compressed density inside the container of at least about0.62 lb/ft³, at least about 0.75 lb/ft³, at least about 0.94 lb/ft³, atleast about 1.25 lb/ft³, at least about 1.56 lb/ft³, and not greaterthan about 3 lb/ft³, not greater than about 2.8 lb/ft³, not greater thanabout 2.5 lb/ft³, not greater than about 2.2 lb/ft³, not greater thanabout 1.87 lb/ft³.

Embodiment 17. The insulation product of any of these embodiments,wherein the second insulation material has a density of at least about0.25 lb/ft³, at least about 0.4 lb/ft³, at least about 1 lb/ft³, atleast about 1.5 lb/ft³, at least about 2 lb/ft³, not greater than about3 lb/ft³, not greater than about 4 lb/ft³, not greater than about 5lb/ft³, not greater than about 6 lb/ft³, not greater than about 8lb/ft³.

Embodiment 18. The insulation product of any of these embodiments,wherein the first insulation material is compressed by at least about10%, at least about 20%, at least about 30%, at least about 40%, atleast about 45%, and not greater than about 80%, not greater than about75%, not greater than about 70%, not greater than about 65%, not greaterthan about 60%.

Embodiment 19. The insulation product of any of these embodiments,wherein a thickness ratio (TR) is defined as a thickness of thecompressed first layer (TF) to a thickness of the second layer (TS), andthe thickness ratio (TR=TF/TS) is at least about 0.1, at least about0.2, at least about 0.3, at least about 0.4, at least about 0.5, and notgreater than about 0.9, not greater than about 0.8, not greater thanabout 0.7, not greater than about 0.6.

Embodiment 20. The insulation product of any of these embodiments,wherein the first layer substantially covers an entire interior surfaceof the container, the second layer substantially covers an entireopposite interior surface of the container, and the second layersubstantially covers and compresses an entire surface of the firstlayer.

Embodiment 21. The insulation product of any of these embodiments,wherein the first insulation material comprises: an uncompressed thermalresistance (R-value) of at least about R10, at least about R11, at leastabout R12, at least about R13, at least about R14, at least about R15,and not greater than about R25, not greater than about R24, not greaterthan about R23, not greater than about R22, not greater than about R21,not greater than about R20; and a compressed R-value of at least aboutR12, at least about R14, at least about R16, at least about R18, atleast about R20, and not greater than about R34, not greater than aboutR32, not greater than about R30, not greater than about R28, not greaterthan about R26.

Embodiment 22. The insulation product of any of these embodiments,wherein the first insulation material comprises: an uncompressed thermalconductivity (λ) of at least about 0.31 Btu·in/(ft²·hr·F), at leastabout 0.30 Btu·in(ft²·hr·F), at least about 0.29 Btu·in(ft²·hr·F), atleast about 0.28 Btu·in(ft²·hr·F), at least about 0.27 Btu·in(ft²·hr·F),and not greater than about 0.22 Btu·in(ft²·hr·F), not greater than about0.23 Btu·in(ft²·hr·F), not greater than about 0.24 Btu·in(ft²·hr·F), notgreater than about 0.25 Btu·in(ft²·hr·F), not greater than about 0.26Btu·in(ft²·hr·F); and a compressed thermal conductivity (λ) of at leastabout 0.31 Btu·in/(ft²·hr·F), at least about 0.30 Btu·in(ft²·hr·F), atleast about 0.29 Btu·in(ft²·hr·F), at least about 0.28 Btu·in(ft²·hr·F),at least about 0.27 Btu·in(ft²·hr·F), and not greater than about 0.21Btu·in(ft²·hr·F), not greater than about 0.22 Btu·in(ft²·hr·F), notgreater than about 0.23 Btu·in(ft²·hr·F), not greater than about 0.24Btu·in(ft²·hr·F), not greater than about 0.25 Btu·in(ft²·hr·F).

Embodiment 23. The insulation product of any of these embodiments,wherein the second insulation material comprises a thermal conductivity(λ) of at least about 0.18 Btu·in/(ft²·hr·F), at least about 0.17Btu·in(ft²·hr·F), at least about 0.16 Btu·in(ft²·hr·F), and not greaterthan about 0.14 Btu·in(ft²·hr·F), not greater than about 0.15Btu·in(ft²·hr·F), not greater than about 0.16 Btu·in(ft²·hr·F).

Embodiment 24. The insulation product of any of these embodiments,wherein the second insulation material comprises a thermal resistance(R-value, aged) of at least about R4/inch, at least about R5/inch, atleast about R5.5/inch, at least about R5.75/inch, and not greater thanabout R7/inch, not greater than about R6.5/inch, not greater than aboutR6.25/inch.

Embodiment 25. The insulation product of any of these embodiments,wherein the insulation product comprises an overall thermal resistance(R-value, aged) of at least about R12, at least about R13, at leastabout R14, at least about R15, at least about R16, and not greater thanabout R23, not greater than about R22, not greater than about R21, notgreater than about R20, not greater than about R19.

Embodiment 26. The insulation product of any of these embodiments,wherein the insulation product has an overall thermal resistance(R-value, aged) of at least about R22, at least about R23, at leastabout R24, at least about R25, at least about R26, and not greater thanabout R36, not greater than about R35, not greater than about R34, notgreater than about R33, not greater than about R32.

Embodiment 27. The insulation product of any of these embodiments,wherein the insulation product has an overall acoustic propertycomprising a noise reduction or Sound Transmission Class (STC) rating ofat least about 33 dB, at least about 34 dB, at least about 35 dB, atleast about 36 dB, at least about 37 dB, and not greater than about 38dB, not greater than about 39 dB, not greater than about 40 dB.

Embodiment 28. The insulation product of any of these embodiments,wherein the container comprises at least one of a natural material, asynthetic material, a board, wood, gypsum, rigid insulation, orientedstrand board (OSB), plywood and particle board.

Embodiment 29. The insulation product of any of these embodiments,wherein the second insulation material comprises an expansion factor ofat least about 2×, at least about 5×, at least about 10×, at least about20×, at least about 50×, at least about 100×, not greater than about200×, not greater than about 400×, not greater than about 600×, notgreater than about 800×, not greater than about 1000×.

Embodiment 30. The insulation product of any of these embodiments,wherein the container comprises a flexural strength of at least about 10lbf, at least about 20 lbf, at least about 30 lbf, at least about 40lbf, at least about 50 lbf, at least about 60 lbf, and not greater thanabout 300 lbf, not greater than about 200 lbf, not greater than about175 lbf, not greater than about 150 lbf, not greater than about 125 lbf,not greater than about 100 lbf.

Embodiment 31. The insulation product of any of these embodiments,wherein the container is portable.

Embodiment 32. The insulation product of any of these embodiments,wherein the container is a rectangular box.

Embodiment 33. The insulation product of any of these embodiments,wherein the rectangular box comprises at least one of: a length of atleast about 1 foot, at least about 3 feet, at least about 5 feet, atleast about 7 feet, at least about 9 feet, and not greater than about 36feet, not greater than about 24 feet, not greater than about 16 feet,not greater than about 14 feet, not greater than about 12 feet; a widthof at least about 6 inches, at least about 8 inches, at least about 10inches, at least about 12 inches, at least about 14 inches, and notgreater than about 16 inches, not greater than about 20 inches, notgreater than about 24 inches, not greater than about 28 inches, notgreater than about 32 inches, not greater than about 36 inches, notgreater than about 40 inches, not greater than about 44 inches, notgreater than about 48 inches; and a depth of at least about 3 inches, atleast about 3.5 inches, at least about 4 inches, at least about 4.5inches, and not greater than about 5 inches, not greater than about 5.5inches, not greater than about 6 inches.

Embodiment 34. The insulation product of any of these embodiments,wherein the first layer is substantially uniform, the second layer issubstantially uniform, and each layer has a flatness (Rmax) of at leastabout 0.08 inches, at least about 0.16 inches, at least about 0.24inches, at least about 0.31 inches, at least about 0.39 inches, notgreater than about 0.79 inches, not greater than about 0.71 inches, notgreater than about 0.63 inches, not greater than about 0.55 inches, notgreater than about 0.47 inches.

Embodiment 35. The insulation product of any of these embodiments,wherein the container can be cut to length, the container can be cut towidth, but the container cannot be cut to depth.

Embodiment 36. The insulation product of any of these embodiments,wherein the second insulation material also is compressed.

Embodiment 37. A method of fabricating an insulation product,comprising: (a) providing a container; (b) installing a first layer of afirst insulation material on an interior surface of the container; andthen (c) installing a second layer of a second insulation materialbetween the first layer and an opposite interior surface of thecontainer, such that the second insulation material expands andcompresses the first layer.

Embodiment 38. The method of any of these embodiments, wherein thecontainer is open during step (b), and the container is closed duringstep (c).

Embodiment 39. The method of any of these embodiments, wherein thecontainer has a single aperture, and step (c) comprises injecting thesecond insulation material through the single aperture.

Embodiment 40. The method of any of these embodiments, wherein thecontainer has a plurality of apertures, and step (c) comprisessimultaneously injecting the second insulation material through all ofthe plurality of apertures.

Embodiment 41. The method of any of these embodiments, wherein step (c)comprises mixing isocyanate and polyol resin.

Embodiment 42. The method of any of these embodiments, furthercomprising at least one of the steps of cutting the container to lengthand cutting the container to width, but not cutting the container todepth.

Embodiment 43. A method of fabricating an insulation product,comprising: (a) defining a structure in a building, the structure havingstuds, claddings mounted to the studs, and structure spaces between thestuds and claddings; (b) installing first layers of a first insulationmaterial and substantially covering a first one of the claddings insiderespective ones of the structure spaces; and then (c) installing secondlayers of a second insulation material in the structure spaces betweenthe first layers and an opposite cladding of the structure, such thatthe second insulation material expands and compresses the first layers.

Embodiment 44. The method of any of these embodiments, wherein thestructure spaces are open during step (b), and the structure spaces areclosed during step (c).

Embodiment 45. The method of any of these embodiments, wherein the firstone of the claddings is an interior cladding, the second one of thecladdings is an exterior cladding, step (b) comprises installing thefirst layers adjacent an interior of the building, and step (c)comprises installing the second layers adjacent an exterior of thebuilding.

Embodiment 46. The method of any of these embodiments, wherein the firstone of the claddings is an exterior cladding, the second one of thecladdings is an interior cladding, step (b) comprises installing thefirst layers adjacent an exterior of the building, and step (c)comprises installing the second layers adjacent an interior of thebuilding.

Embodiment 47. The method of any of these embodiments, wherein thestructure is at least one of a wall with wall spaces, a ceiling withceiling spaces, and a roof with roof spaces.

Embodiment 48. A structure in a building, comprising: studs, first andsecond claddings mounted to opposite sides of the studs, and structurespaces defined between the studs and the opposing claddings; a firstinsulation material comprising first layers on and substantiallycovering a first one of the claddings inside the structure spaces; and asecond insulation material comprising second layers inside the structurespaces, the first layers are compressed and substantially covered by thesecond layers, and the second layers substantially cover a second one ofthe claddings inside the structure spaces.

Embodiment 49. The structure of any of these embodiments, wherein thestructure is at least one of a floor with floor spaces, a wall with wallspaces, a ceiling with ceiling spaces, and a roof with roof spaces.

Embodiment 50. A structure in a building, comprising: studs, first andsecond claddings mounted to opposite sides of the studs, and structurespaces defined between the studs and the claddings; two different typesof insulation in the structure spaces, with a second type of theinsulation compressing a first type of the insulation; and at leastabout 80% of the structure meets a specification comprising: a thermalconductivity (λ) in a range of about 0.14 Btu·in/(ft²·hr·F) to about0.28 Btu·in; a thermal resistance (R-value) in a range of about R13 toabout R22; an acoustic property comprising noise reduction in a range ofabout 33 dB to about 40 dB; and an average density in a range of about0.063 lb/ft³ to about 1.87 lb/ft³.

Embodiment 51. The structure of any of these embodiments, wherein thestructure is at least one of a floor with floor spaces, a wall with wallspaces, a ceiling with ceiling spaces, and a roof with roof spaces.

This written description uses examples to disclose the embodiments,including the best mode, and also to enable those of ordinary skill inthe art to make and use the invention. The patentable scope is definedby the claims, and may include other examples that occur to thoseskilled in the art. Such other examples are intended to be within thescope of the claims if they have structural elements that do not differfrom the literal language of the claims, or if they include equivalentstructural elements with insubstantial differences from the literallanguages of the claims.

Note that not all of the activities described above in the generaldescription or the examples are required, that a portion of a specificactivity may not be required, and that one or more further activitiesmay be performed in addition to those described. Still further, theorder in which activities are listed are not necessarily the order inwhich they are performed.

In the foregoing specification, the concepts have been described withreference to specific embodiments. However, one of ordinary skill in theart appreciates that various modifications and changes can be madewithout departing from the scope of the invention as set forth in theclaims below. Accordingly, the specification and figures are to beregarded in an illustrative rather than a restrictive sense, and allsuch modifications are intended to be included within the scope ofinvention.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,method, article, or apparatus that comprises a list of features is notnecessarily limited only to those features but may include otherfeatures not expressly listed or inherent to such process, method,article, or apparatus. Further, unless expressly stated to the contrary,“or” refers to an inclusive-or and not to an exclusive-or. For example,a condition A or B is satisfied by any one of the following: A is true(or present) and B is false (or not present), A is false (or notpresent) and B is true (or present), and both A and B are true (orpresent).

Also, the use of “a” or “an” are employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of the scope of the invention. This descriptionshould be read to include one or at least one and the singular alsoincludes the plural unless it is obvious that it is meant otherwise.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

After reading the specification, skilled artisans will appreciate thatcertain features are, for clarity, described herein in the context ofseparate embodiments, may also be provided in combination in a singleembodiment. Conversely, various features that are, for brevity,described in the context of a single embodiment, may also be providedseparately or in any subcombination. Further, references to valuesstated in ranges include each and every value within that range.

What is claimed is:
 1. An insulation product formed by a process comprising the steps of: installing a first compressible insulation material on a first interior surface of a structure; installing a second expandable insulation material between the first compressible insulation material and a second interior surface of the structure; and compressing the first compressible insulation material by expanding the second expandable insulation material during the installation of the second expandable insulation material.
 2. The insulation product of claim 1, wherein the first compressible insulation material comprises at least one an organic material, a compressible mineral material, a synthetic material, cellulose, fiberglass, polyester fibers, polyethylene fibers, glass wool, stone wool, sheep wool, wood fibers, cotton, hemp, flax, cork, straw, feathers, and chopped recycled cloth.
 3. The insulation product of claim 2, wherein the first compressible insulation material comprises an uncompressed density of at least about at least about 0.35 lb./ft³ and not greater than about 2.8 lb./ft³ and a compressed density of at least about 0.62 lb./ft³ and not greater than about 3 lb./ft³.
 4. The insulation product of claim 1, wherein the second expandable insulation material comprises at least one of a foam, a spray foam, a slow rise spray foam, and a commercially available expanding foam.
 5. The insulation product of claim 4, wherein the second expandable insulation material comprises a density of at least about 0.25 lb./ft³ and not greater than about 3 lb./ft³.
 6. The insulation product of claim 4, wherein the second expandable insulation material forms an airtight layer.
 7. The insulation product of claim 6, wherein the airtight layer comprises an air permeance of less than about 0.004 L/(s·m²) @ 75 Pa for a one inch thickness.
 8. The insulation product of claim 1, wherein the first compressible insulation material forms a first layer substantially covering the first interior surface, and wherein the second expandable insulation material forms a second layer substantially covering the opposing second interior surface.
 9. The insulation product of claim 8, wherein second expandable insulation material compresses the entire first layer of the first compressible insulation material.
 10. The insulation product of claim 9, wherein the first compressible insulation material comprises at least one of a liner, a facing, and a barrier disposed between the first compressible insulation material and the second expandable insulation material.
 11. The insulation product of claim 9, wherein the first compressible insulation material and the second expandable insulation material substantially fill a cavity formed between the first interior surface and the second interior surface.
 12. The insulation product of claim 1, wherein a thickness ratio (TR) is defined as a thickness of the compressed first compressible insulation material (TF) to a thickness of the second expandable insulation material (TS), and the thickness ratio (TR=TF/TS) is at least about 0.1 and not greater than about 0.9.
 13. The insulation product of claim 1, wherein the first compressible insulation material is compressed by expanding the second expandable insulation material upon installing the second expandable insulation material by at least about 20% and not greater than about 80%.
 14. The insulation product of claim 1, wherein the first compressible insulation material comprises a first R-value, and wherein the insulation product comprises an overall thermal resistance (R-value, aged) after compressing the first compressible insulation material by expanding the second expandable insulation material that is higher than the first R-value.
 15. The insulation product of claim 14, wherein the overall thermal resistance (R-value, aged) is at least about R12 and not greater than about R23.
 16. The insulation product of claim 1, wherein the structure comprises a container, and wherein the container comprises at least one aperture through which the second expandable insulation material is injected.
 17. The insulation product of claim 1, wherein the structure comprises a container, and wherein the container can be cut to length and width.
 18. The insulation product of claim 1, wherein the structure comprises a building, wherein the first interior surface and the second interior surface comprise wall claddings separated by at least two studs in a wall of the building, and wherein a cavity is formed between the first interior surface, the second interior surface, and the at least two studs.
 19. An insulation product formed by a process comprising the steps of: installing a first compressible insulation material to substantially cover a first cladding; and installing a second expandable insulation material between the first compressible insulation material and a second cladding, such that the second expandable insulation material expands and compresses the first compressible insulation against the first cladding during installation, and such that the first compressible insulation material and the second expandable insulation material substantially fill a cavity formed between the first cladding and the second cladding.
 20. The insulation product of claim 19, wherein the first compressible insulation material comprises a first R-value, and wherein the insulation product comprises an overall thermal resistance (R-value, aged) after compressing the first compressible insulation material by expanding the second expandable insulation material that is higher than the first R-value. 